US5000247A - Method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby - Google Patents

Method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby Download PDF

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US5000247A
US5000247A US07/269,308 US26930888A US5000247A US 5000247 A US5000247 A US 5000247A US 26930888 A US26930888 A US 26930888A US 5000247 A US5000247 A US 5000247A
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metal
matrix metal
filler
matrix
infiltration
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US07/269,308
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John T. Burke
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Lanxide Technology Co LP
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Lanxide Technology Co LP
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Priority to US07/269,308 priority Critical patent/US5000247A/en
Assigned to LANXIDE TECHNOLOGY COMPANY, LP, A CORP. OF DE reassignment LANXIDE TECHNOLOGY COMPANY, LP, A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: BURKE, JOHN T.
Priority to IL9173489A priority patent/IL91734A/en
Priority to AU41655/89A priority patent/AU625093B2/en
Priority to AT89630172T priority patent/ATE109212T1/de
Priority to DE68917087T priority patent/DE68917087T2/de
Priority to EP89630172A priority patent/EP0368788B1/en
Priority to KR1019890014117A priority patent/KR0121456B1/ko
Priority to IE318089A priority patent/IE63876B1/en
Priority to NO893987A priority patent/NO177417C/no
Priority to CA002000802A priority patent/CA2000802C/en
Priority to FI894934A priority patent/FI91492C/fi
Priority to NZ231074A priority patent/NZ231074A/en
Priority to CN89108089A priority patent/CN1065792C/zh
Priority to MX018188A priority patent/MX172496B/es
Priority to BR898905612A priority patent/BR8905612A/pt
Priority to PH39468A priority patent/PH26121A/en
Priority to TR89/0759A priority patent/TR25354A/xx
Priority to PT92249A priority patent/PT92249B/pt
Priority to ZA898549A priority patent/ZA898549B/xx
Priority to DK559089A priority patent/DK559089A/da
Priority to RO142380A priority patent/RO107122B1/ro
Priority to JP1291368A priority patent/JP2905520B2/ja
Priority to US07/672,064 priority patent/US5222542A/en
Publication of US5000247A publication Critical patent/US5000247A/en
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
    • C04B41/515—Other specific metals
    • C04B41/5155—Aluminium
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/88—Metals
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1005—Pretreatment of the non-metallic additives
    • C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
    • C22C1/1021—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform the preform being ceramic
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1057—Reactive infiltration
    • C22C1/1063—Gas reaction, e.g. lanxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00905—Uses not provided for elsewhere in C04B2111/00 as preforms
    • C04B2111/00913—Uses not provided for elsewhere in C04B2111/00 as preforms as ceramic preforms for the fabrication of metal matrix comp, e.g. cermets
    • C04B2111/00931—Coated or infiltrated preforms, e.g. with molten metal

Definitions

  • the matrix metal then can be permitted to cool in situ or the mixture of matrix metal and filler material can be poured into a second container as a casting process to form a desired shape which corresponds to the second container.
  • the formed suspension whether cast immediately after being formed or after cooling and thereafter heating and casting, can be pour cast into a desired shape while retaining beneficial characteristics associated with spontaneously infiltrated metal matrix composites.
  • Composite products comprising a metal matrix and a strengthening or reinforcing phase such as ceramic particulates, whiskers, fibers or the like, show great promise for a variety of applications because they combine some of the stiffness and wear resistance of the reinforcing phase with the ductility and toughness of the metal matrix.
  • a metal matrix composite will show an improvement in such properties as strength, stiffness, contact wear resistance, and elevated temperature strength retention relative to the matrix metal in monolithic form, but the degree to which any given property may be improved depends largely on the specific constituents, their volume or weight fraction, and how they are processed in forming the composite. In some instances, the composite also may be lighter in weight than the matrix metal per se.
  • Aluminum matrix composites reinforced with ceramics such as silicon carbide in particulate, platelet, or whisker form, for example, are of interest because of their higher stiffness, wear resistance and high temperature strength relative to aluminum.
  • aluminum does not readily wet alumina, thereby making it difficult to form a coherent product.
  • Various solutions to this problem have been suggested.
  • One such approach is to coat the alumina with a metal (e.g., nickel or tungsten), which is then hot-pressed along with the aluminum.
  • the aluminum is alloyed with lithium, and the alumina may be coated with silica.
  • these composites exhibit variations in properties, or the coatings can degrade the filler, or the matrix contains lithium which can affect the matrix properties.
  • European Patent Application Publication No. 115,742 describes making aluminum-alumina composites, especially useful as electrolytic cell components, by filling the voids of a preformed alumina matrix with molten aluminum.
  • the application emphasizes the non-wettability of alumina by aluminum, and therefore various techniques are employed to wet the alumina throughout the preform.
  • the alumina is coated with a wetting agent of a diboride of titanium, zirconium, hafnium, or niobium, or with a metal, i.e., lithium, magnesium, calcium, titanium, chromium, iron, cobalt, nickel, zirconium, or hafnium.
  • Inert atmospheres, such as argon are employed to facilitate wetting.
  • This reference also shows applying pressure to cause molten aluminum to penetrate an uncoated matrix.
  • infiltration is accomplished by evacuating the pores and then applying pressure to the molten aluminum in an inert atmosphere, e.g., argon.
  • the preform can be infiltrated by vapor-phase aluminum deposition to wet the surface prior to filling the voids by infiltration with molten aluminum
  • heat treatment e.g., at 1400° to 1800° C., in either a vacuum or in argon is required. Otherwise, either exposure of the pressure infiltrated material to gas or removal of the infiltration pressure will cause loss of aluminum from the body.
  • a body e.g., a graphite mold, a steel mold, or a porous refractory material
  • the present invention satisfies these needs by providing a spontaneous infiltration mechanism for infiltrating a material (e.g., a ceramic material), which can be formed into a preform, with molten matrix metal (e.g., aluminum) in the presence of an infiltrating atmosphere (e.g., nitrogen) under normal atmospheric pressures so long as an infiltration enhancer is present at least at some point during the process.
  • a spontaneous infiltration mechanism for infiltrating a material (e.g., a ceramic material), which can be formed into a preform, with molten matrix metal (e.g., aluminum) in the presence of an infiltrating atmosphere (e.g., nitrogen) under normal atmospheric pressures so long as an infiltration enhancer is present at least at some point during the process.
  • a metal matrix composite is produced by infiltrating a permeable mass of filler material (e.g., a ceramic or a ceramic-coated material) with molten aluminum containing at least about 1 percent by weight magnesium, and preferably at least about 3 percent by weight magnesium. Infiltration occurs spontaneously without the application of external pressure or vacuum.
  • filler material e.g., a ceramic or a ceramic-coated material
  • a supply of the molten metal alloy is contacted with the mass of filler material at a temperature of at least about 675° C. in the presence of a gas comprising from about 10 to 100 percent, and preferably at least about 50 percent, nitrogen by volume, and a remainder of the gas, if any, being a nonoxidizing gas, e.g., argon.
  • a gas comprising from about 10 to 100 percent, and preferably at least about 50 percent, nitrogen by volume, and a remainder of the gas, if any, being a nonoxidizing gas, e.g., argon.
  • the molten aluminum alloy infiltrates the ceramic mass under normal atmospheric pressures to form an aluminum (or aluminum alloy) matrix composite.
  • the temperature is lowered to solidify the alloy, thereby forming a solid metal matrix structure that embeds the reinforcing filler material.
  • the supply of molten alloy delivered will be sufficient to permit the infiltration to proceed essentially to the boundaries of the mass of filler material.
  • the amount of filler material in the aluminum matrix composites produced according to the White et al. invention may be exceedingly high. In this respect, filler to alloy volumetric ratios of greater than 1:1 may be achieved.
  • aluminum nitride can form as a discontinuous phase dispersed throughout the aluminum matrix.
  • the amount of nitride in the aluminum matrix may vary depending on such factors as temperature, alloy composition, gas composition and filler material. Thus, by controlling one or more such factors in the system, it is possible to tailor certain properties of the composite. For some end use applications, however, it may be desirable that the composite contain little or substantially no aluminum nitride.
  • the White et al. invention allows the choice of a balance between infiltration kinetics and nitride formation.
  • a barrier means e.g., particulate titanium diboride or a graphite material such as a flexible graphite tape product sold by Union Carbide under the tradename Grafoil®
  • a barrier means is disposed on a defined surface boundary of a filler material and matrix alloy infiltrates up to the boundary defined by the barrier means.
  • the barrier means is used to inhibit, prevent, or terminate infiltration of the molten alloy, thereby providing net, or near net, shapes in the resultant metal matrix composite. Accordingly, the formed metal matrix composite bodies have an outer shape which substantially corresponds to the inner shape of the barrier means.
  • the first source of molten matrix alloy begins to infiltrate the mass of filler material under normal atmospheric pressures and thus begins the formation of a metal matrix composite.
  • the first source of molten matrix metal alloy is consumed during its infiltration into the mass of filler material and, if desired, can be replenished, preferably by a continuous means, from the reservoir of molten matrix metal as the spontaneous infiltration continues.
  • the temperature is lowered to solidify the alloy, thereby forming a solid metal matrix structure that embeds the reinforcing filler material.
  • the reservoir of metal can be present in an amount such that it provides for a sufficient amount of metal to infiltrate the permeable mass of filler material to a predetermined extent.
  • an optional barrier means can contact the permeable mass of filler on at least one side thereof to define a surface boundary.
  • the supply of molten matrix alloy delivered should be at least sufficient to permit spontaneous infiltration to proceed essentially to the boundaries (e.g., barriers) of the permeable mass of filler material
  • the amount of alloy present in the reservoir could exceed such sufficient amount so that not only will there be a sufficient amount of alloy for complete infiltration, but excess molten metal alloy could remain and be attached to the metal matrix composite body.
  • the resulting body will be a complex composite body (e.g., a macrocomposite), wherein an infiltrated ceramic body having a metal matrix therein will be directly bonded to excess metal remaining in the reservoir.
  • a metal matrix composite body is produced by spontaneously infiltrating a permeable mass of filler material with matrix metal.
  • an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material.
  • additional matrix metal (sometimes also referred to herein as a second matrix metal), whether of the same, similar or different composition from the matrix metal which has already infiltrated the filler material, is thereafter added to the infiltrated filler material (e.g., in a preferred embodiment is physically admixed with the infiltrated filler material) to result in a suspension of filler material and matrix metal.
  • a suspension has a lower loading of filler material relative to the matrix metal.
  • an excess of matrix metal is provided, which remains as molten uninfiltrated metal, after spontaneous infiltration is complete. The excess of matrix metal is thereafter stirred or mixed into the infiltrated filler material to form a suspension of filler material and matrix metal having a lower particle loading than the originally spontaneously infiltrated filler material.
  • the spontaneously infiltrated metal matrix composite can be allowed to cool after infiltration is complete.
  • the composite can thereafter be reheated to its liquidus temperature and a second or additional matrix metal can be admixed therewith.
  • a precursor to an infiltration enhancer may be supplied to at least one, or both, of the matrix metal and the filler material.
  • the combination of filler material, matrix metal, supply of infiltration enhancer precursor and infiltrating atmosphere causes the matrix metal to spontaneously infiltrate the filler material.
  • an infiltration enhancer may be supplied directly to at least one of the filler material, and/or matrix metal, and/or infiltrating atmosphere. Ultimately, at least during the spontaneous infiltration, the infiltration enhancer should be located in at least a portion of the filler material.
  • the physical admixing of additional matrix metal can be achieved by mechanical stirring means, ultrasonic stirring means, vibrating means, by hand stirring, or by any other suitable means of mixing the infiltrated filler material with additional matrix metal.
  • the second or additional matrix metal can have a composition which is similar to or quite different from the matrix metal which infiltrated the filler material.
  • the first matrix metal which infiltrated the filler material it would be preferable for the first matrix metal which infiltrated the filler material to be at least partially miscible with the second matrix metal to result in an alloying of the first and second matrix metals and/or the formation of intermetallics of the first and second matrix metals.
  • the second matrix metal is substantially similar to or the same as the first matrix metal which infiltrated the filler material, the two matrix metals are likely to mix quite readily.
  • the resultant metal matrix composite body containing both first and second matrix metals will have a lower volume fraction of filler material relative to a metal matrix composite body which does not contain a second matrix metal therein. Accordingly, the present invention provides a method for producing metal matrix composite bodies having lower volume fractions of filler material. Such lower volume fractions of filler material typically can not be effectively achieved by spontaneously infiltrating a very porous filler material because the maximum amount of porosity that a filler material can exhibit is limited due to such considerations as minimal packing density, preform strength, etc.
  • this application discusses primarily aluminum matrix metals which, at some point during the formation of the metal matrix composite body, are contacted with magnesium, which functions as the infiltration enhancer precursor, in the presence of nitrogen, which functions as the infiltrating atmosphere.
  • the matrix metal/infiltration enhancer precursor/infiltrating atmosphere system of aluminum/magnesium/nitrogen exhibits spontaneous infiltration.
  • other matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems may also behave in a manner similar to the system aluminum/magnesium/nitrogen. For example, similar spontaneous infiltration behavior has been observed in the aluminum/strontium/nitrogen system; the aluminum/zinc/oxygen system; and the aluminum/calcium/nitrogen system. Accordingly, even though the aluminum/magnesium/nitrogen system is discussed primarily herein, it should be understood that other matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems may behave in a similar manner.
  • the aluminum alloy is contacted with a filler material (e.g., alumina or silicon carbide particles).
  • a filler material e.g., alumina or silicon carbide particles.
  • the filler material has admixed therewith, or at some point during the process is exposed to, magnesium, as an infiltration enhancer precursor.
  • the aluminum alloy and/or the filler material at some point during the process, and in this preferred embodiment during substantially all of the process, are exposed to a nitrogen atmosphere.
  • the filler material, and/or the aluminum alloy, and/or the nitrogen infiltrating atmosphere contain magnesium nitride, as an infiltration enhancer.
  • the filler material will be spontaneously infiltrated by the matrix metal and the extent or rate of spontaneous infiltration and formation of metal matrix will vary with a given set of process conditions including, for example, the concentration of magnesium provided to the system (e.g., in the aluminum alloy and/or in the filler material and/or in the infiltrating atmosphere), the size and/or composition of the particles comprising the filler material, the concentration of nitrogen in the infiltrating atmosphere, the time permitted for infiltration, and/or the temperature at which infiltration occurs. Spontaneous infiltration typically occurs to an extent sufficient to embed substantially completely the filler material.
  • Aluminum as used herein, means and includes essentially pure metal (e.g., a relatively pure, commercially available unalloyed aluminum) or other grades of metal and metal alloys such as the commercially available metals having impurities and/or alloying constituents such as iron, silicon, copper, magnesium, manganese, chromium, zinc, etc., therein.
  • An aluminum alloy for purposes of this definition is an alloy or intermetallic compound in which aluminum is the major constituent.
  • Secondary Non-Oxidizing Gas means that any gas present in addition to the primary gas comprising the infiltrating atmosphere is either an inert gas or a reducing gas which is substantially non-reactive with the matrix metal under the process conditions. Any oxidizing gas which may be present as an impurity in the gas(es) used should be insufficient to oxidize the matrix metal to any substantial extent under the process conditions.
  • Barrier or “barrier means”, as used herein, means any suitable means which interferes, inhibits, prevents or terminates the migration, movement, or the like, of molten matrix metal beyond a surface boundary of a permeable mass of filler material or preform, where such surface boundary is defined by said barrier means.
  • Suitable barrier means may be any such material, compound, element, composition, or the like, which, under the process conditions, maintains some integrity and is not substantially volatile (i.e., the barrier material does not volatilize to such an extent that it is rendered nonfunctional as a barrier).
  • suitable "barrier means” includes materials which are substantially non-wettable by the migrating molten matrix metal under the process conditions employed.
  • a barrier of this type appears to exhibit substantially little or no affinity for the molten matrix metal, and movement beyond the defined surface boundary of the mass of filler material or preform is prevented or inhibited by the barrier means.
  • the barrier reduces any final machining or grinding that may be required and defines at least a portion of the surface of the resulting metal matrix composite product.
  • the barrier may in certain cases be permeable or porous, or rendered permeable by, for example, drilling holes or puncturing the barrier, to permit gas to contact the molten matrix metal.
  • Carcass or “Carcass of Matrix Metal”, as used herein, refers to any of the original body of matrix metal remaining which has not been consumed during formation of the metal matrix composite body, and typically, if allowed to cool, remains in at least partial contact with the metal matrix composite body which has been formed. It should be understood that the carcass may also include a second or foreign metal therein.
  • Fillers is intended to include either single constituents or mixtures of constituents which are substantially non-reactive with and/or of limited solubility in the matrix metal and may be single or multi-phase. Fillers may be provided in a wide variety of forms, such as powders, flakes, platelets, microspheres, whiskers, bubbles, etc., and may be either dense or porous. "Filler” may also include ceramic fillers, such as alumina or silicon carbide as fibers, chopped fibers, particulates, whiskers, bubbles, spheres, fiber mats, or the like, and ceramic-coated fillers such as carbon fibers coated with alumina or silicon carbide to protect the carbon from attack, for example, by a molten aluminum parent metal. Fillers may also include metals.
  • Infiltrating Atmosphere means that atmosphere which is present which interacts with the matrix metal and/or preform (or filler material) and/or infiltration enhancer precursor and/or infiltration enhancer and permits or enhances spontaneous infiltration of the matrix metal to occur.
  • Infiltration Enhancer means a material which promotes or assists in the spontaneous infiltration of a matrix metal into a filler material or preform.
  • An infiltration enhancer may be formed from, for example, a reaction of an infiltration enhancer precursor with an infiltrating atmosphere to form (1) a gaseous species and/or (2) a reaction product of the infiltration enhancer precursor and the infiltrating atmosphere and/or (3) a reaction product of the infiltration enhancer precursor and the filler material or preform.
  • the infiltration enhancer may be supplied directly to at least one of the preform, and/or matrix metal, and/or infiltrating atmosphere and function in a substantially similar manner to an infiltration enhancer which has formed as a reaction between an infiltration enhancer precursor and another species.
  • the infiltration enhancer should be located in at least a portion of the filler material or preform to achieve spontaneous infiltration.
  • Infiltration Enhancer Precursor or "Precursor to the Infiltration Enhancer”, as used herein, means a material which when used in combination with the matrix metal, preform and/or infiltrating atmosphere forms an infiltration enhancer which induces or assists the matrix metal to spontaneously infiltrate the filler material or preform.
  • the precursor to the infiltration enhancer it appears as though it may be necessary for the precursor to the infiltration enhancer to be capable of being positioned, located or transportable to a location which permits the infiltration enhancer precursor to interact with the infiltrating atmosphere and/or the preform or filler material and/or metal.
  • the infiltration enhancer precursor in some matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems, it is desirable for the infiltration enhancer precursor to volatilize at, near, or in some cases, even somewhat above the temperature at which the matrix metal becomes molten.
  • volatilization may lead to: (1) a reaction of the infiltration enhancer precursor with the infiltrating atmosphere to form a gaseous species which enhances wetting of the filler material or preform by the matrix metal; and/or (2) a reaction of the infiltration enhancer precursor with the infiltrating atmosphere to form a solid, liquid or gaseous infiltration enhancer in at least a portion of the filler material or preform which enhances wetting; and/or (3) a reaction of the infiltration enhancer precursor within the filler material or preform which forms a solid, liquid or gaseous infiltration enhancer in at least a portion of the filler material or preform which enhances wetting.
  • Low Particle Loading or “Lower Volume Fraction of Filler Material”, as used herein, means that the amount of matrix metal relative to filler material has been increased relative to a filler material which is spontaneously infiltrated without having an additional or second matrix alloy added thereto.
  • Microx Metal or “Matrix Metal Alloy”, as used herein, means that metal which is utilized to form a metal matrix composite (e.g., before infiltration) and/or that metal which is intermingled with a filler material to form a metal matrix composite body (e.g., after infiltration).
  • a specified metal is mentioned as the matrix metal, it should be understood that such matrix metal includes that metal as an essentially pure metal, a commercially available metal having impurities and/or alloying constituents therein, an intermetallic compound or an alloy in which that metal is the major or predominant constituent.
  • Metal/Infiltration Enhancer Precursor/Infiltrating Atmosphere System or “Spontaneous System”, as used herein, refers to that combination of materials whichs exhibit spontaneous infiltration into a preform or filler material. It should be understood that whenever a “/" appears between an exemplary matrix metal, infiltration enhancer precursor and infiltrating atmosphere, the "/" is used to designate a system or combination of materials which, when combined in a particular manner, exhibits spontaneous infiltration into a preform or filler material.
  • Metal Matrix Composite or “MMC”, as used herein, means a material comprising a two- or three-dimensionally interconnected alloy or matrix metal which has embedded a preform or filler material.
  • the matrix metal may include various alloying elements to provide specifically desired mechanical and physical properties in the resulting composite.
  • a Metal "Different" from the Matrix Metal means a metal which does not contain, as a primary constituent, the same metal as the matrix metal (e.g., if the primary constituent of the matrix metal is aluminum, the "different" metal could have a primary constituent of, for example, nickel).
  • Nonreactive Vessel for Housing Matrix Metal means any vessel which can house or contain a filler material (or preform) and/or molten matrix metal under the process conditions and not react with the matrix and/or the infiltrating atmosphere and/or infiltration enhancer precursor and/or a filler material (or preform) in a manner which would be significantly detrimental to the spontaneous infiltration mechanism.
  • Preform or “Permeable Preform”, as used herein, means a porous mass of filler or filler material which is manufactured with at least one surface boundary which essentially defines a boundary for infiltrating matrix metal, such mass retaining sufficient shape integrity and green strength to provide dimensional fidelity prior to being infiltrated by the matrix metal.
  • the mass should be sufficiently porous to accommodate spontaneous infiltration of the matrix metal thereinto.
  • a preform typically comprises a bonded array or arrangement of filler, either homogeneous or heterogeneous, and may be comprised of any suitable material (e.g., ceramic and/or metal particulates, powders, fibers, whiskers, etc., and any combination thereof).
  • a preform may exist either singularly or as an assemblage.
  • Reservoir means a separate body of matrix metal positioned relative to a mass of filler or a preform so that, when the metal is molten, it may flow to replenish, or in some cases to initially provide and subsequently replenish, that portion, segment or source of matrix metal which is in contact with the filler or preform.
  • “Second Matrix Metal” or “Additional Matrix Metal”, as used herein, means that metal which remains or which is added after spontaneous infiltration of the filler material has been completed or substantially completed, and which is admixed with the infiltrated filler material to form a suspension of infiltrated filler material and first and second (or additional) matrix metals, thereby forming a lower volume fraction of filler material, such second or additional matrix metal having a composition which either is exactly the same as, similar to or substantially different from the matrix metal which has previously spontaneously infiltrated the filler material.
  • “Spontaneous Infiltration” means the infiltration of matrix metal into the permeable mass of filler or preform occurs without requirement for the application of pressure or vacuum (whether externally applied or internally created).
  • “Suspension of Filler Material and Matrix Metal” or “Suspension”, as used herein, means the mixture of second or additional matrix metal and filler material which has been spontaneously infiltrated by a first matrix metal.
  • FIG. 1a is a schematic cross-sectional view of a lay-up in accordance with the present invention, illustrating a partially infiltrated composite with excess matrix metal;
  • FIG. 1b is a schematic cross-sectional view illustrating the dispersion of an infiltrated composite and excess matrix metal
  • FIG. 1c is a schematic cross-sectional view of the dispersed infiltrated composite before further processing
  • FIG. 1d is a schematic cross-sectional view illustrating the pourability of the dispersed composite.
  • FIG. 2 is a schematic cross-sectional view of the lay-up of Examples 1-4.
  • high particle loadings are obtainable from spontaneous infiltration techniques as disclosed, for example, in commonly owned U.S. patent application Ser. No. 049,I71, filed May 13, 1987
  • lower particle loadings are more difficult, in some cases, to obtain using only such techniques.
  • preforms or filler material having very high porosity may be required.
  • the porosity ultimately obtainable with such filler materials or preforms is limited, such porosity being a function of the particular filler material employed and the size or granularity of the particles used in the preform.
  • spontaneous infiltration techniques are utilized to obtain the advantageous properties heretofore associated with spontaneously infiltrated metal matrix composites, yet lower particle loadings are obtainable.
  • a metal matrix composite body is formed by first spontaneously infiltrating a filler material with a first matrix metal in an infiltrating atmosphere and thereafter adding additional or second matrix metal to the infiltrated filler material to result in a suspension of lower volume fraction of filler material and matrix metal.
  • the addition of the additional or second matrix metal enables the process to be tailored to provide a metal matrix of the first matrix metal (i.e., where the first and second matrix metals are the same) or an intermetallic or alloy of the first and second matrix metals (i.e., where the first and second matrix metals are different).
  • FIG. 1a illustrates a lay-up (10) which could be used in accordance with the present invention.
  • a filler material (or preform) (1) is provided in a mold or container (2), which is substantially non-reactive with the components.
  • a matrix metal (3) is provided, and is heated above its melting point under conditions which enable spontaneous infiltration to occur, as discussed in more detail below.
  • a metal matrix composite (4) is formed (e.g., if the matrix metal was permitted to cool, at least the portion (4) would comprise a metal matrix composite).
  • an excess of matrix metal (3) is provided, such that upon completion of spontaneous infiltration, a carcass of uninfiltrated matrix metal remains.
  • the matrix metal composite while still molten, is admixed with excess matrix metal via a stirrer (5), such that the infiltrated filler material is dispersed into the additional matrix metal to form a suspension.
  • Stirrer (5) can be any conventional stirring apparatus, including mechanical stirring means, ultrasonic stirring means or hand stirring. Stirring is continued for 1 to 15 minutes, and preferably for 10 to 15 minutes, or until a homogeneous, fully dispersed mixture (7) is obtained, as illustrated by FIG. 1c.
  • Stirring should preferably be undertaken at spontaneous infiltration process temperatures (discussed below) to avoid hardening of the composite before dispersion of the mixture is complete.
  • Such stirring could be effected, for example, via overhead stirring means provided in the furnace.
  • procedures should be undertaken to avoid premature cooling, including the use of heated stirring apparatus and well-insulated containment vessels, etc.
  • the dispersed mixture can be poured, as illustrated in FIG. 1d, into a mold to form a body having a lower particle loading than is otherwise obtainable via spontaneous infiltration.
  • a mold Any conventional mold can be used, such as investment shell molds, split shell molds, multiple piece molds, reusable molds, and the like.
  • the molds preferably, are heated to delay cooling of the dispersed composite to maximize pour times and workability of the poured dispersed composite.
  • room temperature molds or cooled molds e.g., a copper chill plate, can be utilized if quicker cooling is desired in a particular application.
  • the container in which the composite is dispersed corresponds to the ultimate desired shape of the body to be formed. Accordingly, rather than pouring the suspension of filler material and matrix metal, it is allowed to cool in the container, such that the container performs the function of the mold.
  • the suspension can be allowed to cool, and can thereafter be reheated above its melting point and poured or molded for further processing or forming.
  • the suspension can be poured into a mold to form an intermediate body, e.g., an ingot, which can thereafter be used as a precursor to further processing.
  • the resulting composite from the above embodiments exhibits the highly desirable properties associated with other spontaneously infiltrated composites. Moreover, lower particle loadings are obtainable, e.g., of the order of 5 to 40 volume percent, using the dispersion methods of the present invention.
  • an excess of matrix metal is not used as in FIG. 1a. Instead, a bed of filler material or a preform is spontaneously infiltrated and allowed to cool. The infiltrated metal matrix composite is thereafter reheated and additional matrix metal is dispersed therein in accordance with the procedures discussed above to create a low particle loading metal matrix composite. Alternatively, the additional matrix metal can be added while the matrix metal in the infiltrated composite is still in its liquidus state.
  • the additional or second matrix metal in all of the above embodiments can have a composition which is the same as, similar to or quite different from the matrix metal which spontaneously infiltrates the filler or preform.
  • the resultant three dimensionally interconnected metal matrix of the metal matrix composite can be varied to provide any of a variety of alloys or intermetallics to suit a particular application.
  • desired chemical, electrical, mechanical and other properties can be tailored to suit a particular application.
  • the second matrix metal is, preferably, a metal which is miscible with the first matrix metal.
  • the second matrix metal can be introduced in many different ways.
  • matrix metal (3) could be a multi-phase molten alloy having stratified layers comprised at its surface adjacent to the interface with the filler of a first matrix metal, but having at its upper end a second matrix metal.
  • the first matrix metal can be, for example, rich in infiltration enhancer and/or infiltration enhancer precursor and/or secondary alloys which promote infiltration.
  • the second or additional matrix metal can be admixed to the suspension in accordance with FIG. 1b.
  • the second or additional matrix metal can be poured in or added in its solid form and liquefied, after spontaneous infiltration has occurred.
  • a metal matrix composite can be formed and cooled and, in a subsequent processing step, the composite can be reheated and the second or additional matrix metal can be dispersed into the suspension.
  • an infiltration enhancer should be provided to the spontaneous system.
  • An infiltration enhancer could be formed from an infiltration enhancer precursor which could be provided (1) in the matrix metal; and/or (2) in the preform; and/or (3) from the infiltrating atmosphere; and/or (4) from an external source into the spontaneous system.
  • an infiltration enhancer may be supplied directly to at least one of the preform, and/or matrix metal, and/or infiltrating atmosphere.
  • the infiltration enhancer should be located in at least a portion of the filler material.
  • the infiltration enhancer precursor can be at least partially reacted with the infiltrating atmosphere such that infiltration enhancer can be formed in at least a portion of the filler prior to or substantially contiguous with contacting the filler material with the matrix metal (e.g., if magnesium was the infiltration enhancer precursor and nitrogen was the infiltrating atmosphere, the infiltration enhancer could be magnesium nitride which would be located in at least a portion of the filler material).
  • an aluminum matrix metal can be contained within a suitable refractory vessel which, under the process conditions, does not react with the aluminum matrix metal and/or the filler material when the aluminum is made molten.
  • a filler material can then be contacted with the molten aluminum matrix metal. Under the process conditions, the aluminum matrix metal is induced to infiltrate the filler material spontaneously.
  • the filler material should be sufficiently permeable to permit the nitrogen-containing gas to penetrate or permeate the molten material at some point during the process and/or contact the molten matrix metal.
  • the permeable preform can accommodate infiltration of the molten matrix metal, thereby causing the nitrogen-permeated preform to be infiltrated spontaneously with molten matrix metal to form a metal matrix composite body and/or cause the nitrogen to react with an infiltration enhancer precursor to form infiltration enhancer in the preform and thereby resulting in spontaneous infiltration.
  • the extent of spontaneous infiltration and formation of the metal matrix composite will vary with a given set of process conditions, including magnesium or magnesium nitride content of the aluminum alloy, magnesium or magnesium nitride content of the filler material, amount of magnesium or magnesium nitride in the filler material, the presence of additional alloying elements (e.g., silicon, iron, copper, manganese, chromium, zinc, and the like), average size of the materials comprising the filler material (e.g., particle diameter) surface condition and type of filler material, nitrogen concentration of the infiltrating atmosphere, time permitted for infiltration and temperature at which infiltration occurs.
  • additional alloying elements e.g., silicon, iron, copper, manganese, chromium, zinc, and the like
  • average size of the materials comprising the filler material e.g., particle diameter
  • nitrogen concentration of the infiltrating atmosphere time permitted for infiltration and temperature at which infiltration occurs.
  • the aluminum can be alloyed with at least about 1 percent by weight, and preferably at least about 3 percent by weight, magnesium (which functions as the infiltration enhancer precursor), based on alloy weight.
  • magnesium which functions as the infiltration enhancer precursor
  • auxiliary alloying elements may also be included in the matrix metal to tailor specific properties thereof. (Additionally, the auxiliary alloying elements may affect the minimum amount of magnesium required in the matrix aluminum metal to result in spontaneous infiltration of the filler material or preform.) Loss of magnesium from the spontaneous system due to, for example, volatilization should not occur to such an extent that no magnesium was present to form infiltration enhancer.
  • the volume percent of nitrogen in the nitrogen atmosphere also affects formation rates of the metal matrix composite body. Specifically, if less than about 10 volume percent of nitrogen is present in the infiltrating atmosphere, very slow or little spontaneous infiltration will occur. It has been discovered that it is preferable for at least about 50 volume percent of nitrogen to be present in the atmosphere, thereby resulting in, for example, shorter infiltration times due to a much more rapid rate of infiltration.
  • the infiltrating atmosphere e.g., a nitrogen-containing gas
  • the minimum magnesium content required for molten matrix metal to infiltrate a filler material or preform depends on one or more variables such as the processing temperature, time, the presence of auxiliary alloying elements such as silicon or zinc, the nature of the filler material, the location of the magnesium in one or more components of the spontaneous system, the nitrogen content of the atmosphere, and the rate at which the nitrogen atmosphere flows. Lower temperatures or shorter heating times can be used to obtain complete infiltration as the magnesium content of the alloy and/or preform is increased. Also, for a given magnesium content, the addition of certain auxiliary alloying elements such as zinc permits the use of lower temperatures.
  • a magnesium content of the matrix metal at the lower end of the operable range may be used in conjunction with at least one of the following: an above-minimum processing temperature, a high nitrogen concentration, or one or more auxiliary alloying elements.
  • an above-minimum processing temperature e.g., from about 1 to 3 weight percent
  • auxiliary alloying elements e.g., one or more auxiliary alloying elements.
  • alloys containing from about 3 to 5 weight percent magnesium are preferred on the basis of their general utility over a wide variety of process conditions, with at least about 5 percent being preferred when lower temperatures and shorter times are employed.
  • Magnesium contents in excess of about 10 percent by weight of the aluminum alloy may be employed to moderate the temperature conditions required for infiltration.
  • the magnesium content may be reduced when used in conjunction with an auxiliary alloying element, but these elements serve an auxiliary function only and are used together with at least the above-specified minimum amount of magnesium.
  • auxiliary alloying element for example, there was substantially no infiltration of nominally pure aluminum alloyed only with 10 percent silicon at 1000° C. into a bedding of 500 mesh, 39 Crystolon (99 percent pure silicon carbide from Norton Co.).
  • silicon has been found to promote the infiltration process.
  • the amount of magnesium varies if it is supplied exclusively to the preform or filler material. It has been discovered that spontaneous infiltration will occur with a lesser weight percent of magnesium supplied to the spontaneous system when at least some of the total amount of magnesium supplied is placed in the preform or filler material.
  • the preform may be desirable for a lesser amount of magnesium to be provided in order to prevent the formation of undesirable intermetallics in the metal matrix composite body.
  • a silicon carbide preform it has been discovered that when the preform is contacted with an aluminum matrix metal, the preform containing at least about 1% by weight magnesium and being in the presence of a substantially pure nitrogen atmosphere, the matrix metal spontaneously infiltrates the preform.
  • the amount of magnesium required to achieve acceptable spontaneous infiltration is slightly higher.
  • the spontaneous system infiltration enhancer precursor and/or infiltration enhancer on a surface of the alloy and/or on a surface of the preform or filler material and/or within the preform or filler material prior to infiltrating the matrix metal into the filler material or preform (i.e., it may not be necessary for the supplied infiltration enhancer or infiltration enhancer precursor to be alloyed with the matrix metal, but rather, simply supplied to the spontaneous system).
  • the magnesium was applied to a surface of the matrix metal, it may be preferred that said surface should be the surface which is closest to, or preferably in contact with, the permeable mass of filler material or vice versa; or such magnesium could be mixed into at least a portion of the preform or filler material.
  • infiltration enhancer(s) and/or infiltration enhancer precursor(s) could result in a decrease in the total weight percent of magnesium needed to promote infiltration of the matrix aluminum metal into the preform, as well as achieving lower temperatures at which infiltration can occur.
  • the amount of undesirable intermetallics formed due to the presence of magnesium could also be minimized.
  • auxiliary alloying elements and the concentration of nitrogen in the surrounding gas also affects the extent of nitriding of the matrix metal at a given temperature.
  • auxiliary alloying elements such as zinc or iron included in the alloy, or placed on a surface of the alloy, may be used to reduce the infiltration temperature and thereby decrease the amount of nitride formation, whereas increasing the concentration of nitrogen in the gas may be used to promote nitride formation.
  • the temperature also may vary with different filler materials. In general, spontaneous and progressive infiltration will occur at a process temperature of at least about 675° C., and preferably a process temperature of at least about 750° C.-800° C. Moreover, satisfactory pourability of the resulting suspension, after the second matrix metal has been dispersed, is achievable at or about 800° C. or greater, and possibly lower, depending upon the nature of the suspension. Pourability does not necessarily improve with increased temperatures. Temperatures generally in excess of 1200° C.
  • the spontaneous infiltration temperature is a temperature which is above the melting point of the matrix metal but below the volatilization temperature of the matrix metal. Moreover, the spontaneous infiltration temperature should be below the melting point of the filler material. Still further, as temperature is increased, the tendency to form a reaction product between the matrix metal and infiltrating atmosphere increases (e.g., in the case of aluminum matrix metal and a nitrogen infiltrating atmosphere, aluminum nitride may be formed). Such reaction product may be desirable or undesirable based upon the intended application of the metal matrix composite body. Additionally, electric resistance heating is typically used to achieve the infiltrating temperatures. However, any heating means which can cause the matrix metal to become molten and does not adversely affect spontaneous infiltration, is acceptable for use with the invention.
  • a permeable filler material comes into contact with molten aluminum in the presence of, at least some time during the process, a nitrogen-containing gas.
  • the nitrogen-containing gas may be supplied by maintaining a continuous flow of gas into contact with at least one of the filler material and molten aluminum matrix metal.
  • the flow rate of the nitrogen-containing gas is not critical, it is preferred that the flow rate be sufficient to compensate for any nitrogen lost from the atmosphere due to nitride formation in the alloy matrix, and also to prevent or inhibit the incursion of air which can have an oxidizing effect on the molten metal.
  • suitable filler materials include (a) oxides, e.g. alumina; (b) carbides, e.g. silicon carbide; (c) borides, e.g. aluminum dodecaboride, and (d) nitrides, e.g. aluminum nitride.
  • the filler material may comprise a substrate, such as carbon or other non-ceramic material, bearing a ceramic coating to protect the substrate from attack or degradation.
  • Suitable ceramic coatings include oxides, carbides, borides and nitrides. Ceramics which are preferred for use in the present method include alumina and silicon carbide in the form of particles, platelets, whiskers and fibers.
  • the fibers can be discontinuous (in chopped form) or in the form of continuous filament, such as multifilament tows.
  • the filler material or preform may be homogeneous or heterogeneous.
  • Alumina and silicon carbide both provide satisfactory suspensions when a second or additional matrix metal is dispersed therein in accordance with the invention.
  • silicon carbide has been found to be more pourable then alumina after dispersion into a suspension.
  • crushed alumina bodies made by the method disclosed in U.S. Pat. No. 4,713,360, entitled “Novel Ceramic Materials and Methods of Making Same", which issued on Dec. 15, 1987, in the names of Marc S. Newkirk et al. exhibit desirable infiltration properties relative to commercially available alumina products.
  • crushed alumina bodies made by the method disclosed in Copending and Commonly Owned application Ser. No. 819,397, entitled “Composite Ceramic Articles and Methods of Making Same", in the names of Marc S. Newkirk et al. also exhibit desirable infiltration properties relative to commercially available alumina products.
  • the size and shape of the filler material can be any that may be required to achieve the properties desired in the composite.
  • the material may be in the form of particles, whiskers, platelets or fibers since infiltration is not restricted by the shape of the filler material. Other shapes such as spheres, tubules, pellets, refractory fiber cloth, and the like may be employed.
  • the size of the material does not limit infiltration, although a higher temperature or longer time period may be needed for complete infiltration of a mass of smaller particles than for larger particles.
  • the mass of filler material (shaped into a preform) to be infiltrated should be permeable (i.e., permeable to molten matrix metal and to the infiltrating atmosphere).
  • the method of forming metal matrix composites according to the present invention permits the production of substantially uniform metal matrix composites having a high volume fraction of filler material and low porosity.
  • Higher volume fractions of filler material may be achieved by using a lower porosity initial mass of filler material.
  • Higher volume fractions also may be achieved if the mass of filler is compacted or otherwise densified provided that the mass is not converted into either a compact with close cell porosity or into a fully dense structure that would prevent infiltration by the molten alloy.
  • low volume fractions or particle loadings are also obtainable. Accordingly, a wide range of particle loadings can be achieved while still obtaining the processing advantages and properties associated with spontaneous infiltration.
  • the specific process temperature at which nitride formation becomes more pronounced also varies with such factors as the matrix aluminum alloy used and its quantity relative to the volume of filler material, the filler material to be infiltrated, and the nitrogen concentration of the infiltrating atmosphere.
  • the extent of aluminum nitride formation at a given process temperature is believed to increase as the ability of the alloy to wet the filler decreases and as the nitrogen concentration of the atmosphere increases.
  • the process conditions can be selected to control the nitride formation.
  • a composite product containing an aluminum nitride phase will exhibit certain properties which can be favorable to, or improve the performance of, the product.
  • the temperature range for spontaneous infiltration with an aluminum alloy may vary with the ceramic material used. In the case of alumina as the filler material, the temperature for infiltration should preferably not exceed about 1000° C. if it is desired that the ductility of the matrix not be reduced by the significant formation of nitride. However, temperatures exceeding 1000° C. may be employed if it is desired to produce a composite with a less ductile and stiffer matrix. To infiltrate silicon carbide, higher temperatures of about 1200° C. may be employed since the aluminum alloy nitrides to a lesser extent, relative to the use of alumina as filler, when silicon carbide is employed as a filler material.
  • a reservoir of matrix metal to assure complete infiltration of the filler material and/or to supply a second metal which has a different composition from the first source of matrix metal.
  • a matrix metal in the reservoir which differs in composition from the first source of matrix metal.
  • an aluminum alloy is used as the first source of matrix metal
  • virtually any other metal or metal alloy which was molten at the processing temperature could be used as the reservoir metal.
  • Molten metals frequently are very miscible with each other which would result in the reservoir metal mixing with the first source of matrix metal so long as an adequate amount of time is given for the mixing to occur.
  • a reservoir metal which is different in composition than the first source of matrix metal it is possible to tailor the properties of the metal matrix to meet various operating requirements and thus tailor the properties of the metal matrix composite.
  • a barrier means may also be utilized in combination with the present invention. Suitable barrier means may be required in the container 2 in which initial infiltration occurs, as well as in any mold into which the dispersed suspension is to be poured. Specifically, the barrier means for use with this invention may be any suitable means which interferes, inhibits, prevents or terminates the migration, movement, or the like, of molten matrix alloy (e.g., an aluminum alloy) beyond the defined surface boundary of the filler material.
  • molten matrix alloy e.g., an aluminum alloy
  • Suitable barrier means may be any material, compound, element, composition, or the like, which, under the process conditions of this invention, maintains some integrity, is not volatile and preferably is permeable to the gas used with the process as well as being capable of locally inhibiting, stopping, interfering with, preventing, or the like, continued infiltration or any other kind of movement beyond the defined surface boundary of the filler material.
  • Suitable barrier means includes materials which are substantially non-wettable by the migrating molten matrix alloy under the process conditions employed.
  • a barrier of this type appears to exhibit little or no affinity for the molten matrix alloy, and movement beyond the defined surface boundary of the filler material or preform is prevented or inhibited by the barrier means.
  • the barrier reduces any final machining or grinding that may be required of the metal matrix composite product.
  • the barrier preferably should be permeable or porous, or rendered permeable by puncturing, to permit the gas to contact the molten matrix alloy.
  • Suitable barriers particularly useful for aluminum matrix alloys are those containing carbon, especially the crystalline allotropic form of carbon known as graphite.
  • Graphite is essentially non-wettable by the molten aluminum alloy under the described process conditions.
  • a particularly preferred graphite is a graphite tape product that is sold under the trademark Grafoil®, registered to Union Carbide. This graphite tape exhibits sealing characteristics that prevent the migration of molten aluminum alloy beyond the defined surface boundary of the filler material. This graphite tape is also resistant to heat and is chemically inert.
  • Grafoil® graphite material is flexible, compatible, conformable and resilient. It can be made into a variety of shapes to fit any barrier application.
  • graphite barrier means may be employed as a slurry or paste or even as a paint film around and on the boundary of the filler material or preform.
  • Grafoil® is particularly preferred because it is in the form of a flexible graphite sheet. In use, this paperlike graphite is simply formed around the filler material or preform.
  • transition metal borides e.g., titanium diboride (TiB 2 )
  • TiB 2 titanium diboride
  • the transition metal borides are typically in a particulate form (1-30 microns).
  • the barrier materials may be applied as a slurry or paste to the boundaries of the permeable mass of ceramic filler material which preferably is preshaped as a preform.
  • barrier barriers for aluminum metal matrix alloys in nitrogen include low-volatile organic compounds applied as a film or layer onto the external surface of the filler material or preform. Upon firing in nitrogen, especially at the process conditions of this invention, the organic compound decomposes leaving a carbon soot film.
  • the organic compound may be applied by conventional means such as painting, spraying, dipping, etc.
  • finely ground particulate materials can function as a barrier so long as infiltration of the particulate material would occur at a rate which is slower than the rate of infiltration of the filler material.
  • the barrier means may be applied by any suitable means, such as by covering the defined surface boundary with a layer of the barrier means.
  • a layer of barrier means may be applied by painting, dipping, silk screening, evaporating, or otherwise applying the barrier means in liquid, slurry, or paste form, or by sputtering a vaporizable barrier means, or by simply depositing a layer of a solid particulate barrier means, or by applying a solid thin sheet or film of barrier means onto the defined surface boundary.
  • the following examples illustrate the spontaneous infiltration of a filler material with a matrix metal, and the subsequent dispersion of additional matrix metal, to obtain a fully dispersed, homogeneous, pourable suspension, having a substantially lower particle loading than the undispersed spontaneously infiltrated composite.
  • FIG. 2 illustrates schematically the lay-up for Examples 1 and 2.
  • the experiments for Examples 1 and 2 were performed simultaneously and side-by-side.
  • a 316 stainless steel can (101), 6 inches in diameter and 4.5 inches in height, was lined with Permafoil®, which functioned as a non-reactive container for spontaneous infiltration.
  • Example 1 about 300 g of filler (102) comprised of a mixture of silicon carbide (1000 grit 39 Crystolon from Norton Company) and about 2 percent magnesium (325 mesh) was provided. An ingot (103) of about 600 g of an aluminium alloy containing about 12 weight percent silicon about 5 weight percent zinc and about 6 weight percent magnesium (Al-12Si-5Zn-6Mg) was placed on top of the filler (102). A layer of 50 mesh magnesium powder was placed at the interface between the filler (102) and the ingot (103).
  • filler (102) comprised of a mixture of silicon carbide (1000 grit 39 Crystolon from Norton Company) and about 2 percent magnesium (325 mesh) was provided.
  • Example 2 about 300 g of filler (104) comprised of a mixture of alumina (1000 grit E67 Alundum from Norton Company) and 5 percent magnesium (325 mesh) was provided. An ingot (105) of about 600 g of a standard aluminum 520 alloy (containing 10 percent magnesium) was placed on top of the filler (104). Again, a layer of 50 mesh magnesium was placed at the interface between the filler (104) and the ingot (105).
  • Both stainless steel containers (101) were placed in a 14 inch long by 8 inch wide by 7 inch high 316 stainless steel can (106), which was covered with copper foil (108).
  • a layer of Fiberfrax® 107 was placed at the bottom of can (106) to insulate the smaller cans (101) from the bottom of the furnace floor.
  • a titanium sponge (109) was placed along the bottom of the larger can to absorb any oxygen which might enter the system.
  • a 2:1 ratio (by weight) of matrix metal to filler was utilized in Examples 1 and 2 to ensure that there was an excess of matrix metal, and that a reserve of additional matrix metal would remain after spontaneous infiltration was complete.
  • the 2:1 ratio, after dispersion, was selected to create a 33 percent (by weight) loading of particles to matrix metal.
  • lay-up (100) was then placed in a furnace, purged with nitrogen via inlet (110), and heated from room temperature to about 800° C. over a period of about 2 hours under a flow of nitrogen gas at a flow rate of about 2.5 l/min. for approximately 2 hours until spontaneous infiltration was substantially complete.
  • Cans (101) containing the spontaneously infiltrated composites were thereafter removed from the furnace at 800° C. and stirred immediately by hand in air for 2-3 minutes with an alumina stirring rod, which also had been heated to the furnace temperature.
  • Example 1 the silicon carbide filler
  • Example 2 the alumina filler
  • Both examples demonstrated the applicability of the dispersion method of the present invention to convert unmoldable and unpourable metal matrix composites having particle loadings of the order of 50 percent to a pourable composite having a particle loading of the order of 30 percent.
  • Example 1 and 2 were identically repeated as Examples 3 and 4, respectively, except that a set-point furnace temperature of 850° C. was used in an attempt to render the composites (e.g., the suspensions) more pourable.
  • Example 3 was harder to stir and pour than the suspension of Example 1. This diminished stirrability and pourability, however, may have been the result of more complete spontaneous infiltration before mixing in Example 3 than in Example 1 resulting in better particle wetting.
  • Example 4 did not show any change in pourability as compared to the alumina filler and matrix suspension of Example 2.

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US07/269,308 1988-11-10 1988-11-10 Method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby Expired - Lifetime US5000247A (en)

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Application Number Priority Date Filing Date Title
US07/269,308 US5000247A (en) 1988-11-10 1988-11-10 Method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby
IL9173489A IL91734A (en) 1988-11-10 1989-09-21 Method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby
AU41655/89A AU625093B2 (en) 1988-11-10 1989-09-22 A method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby
DE68917087T DE68917087T2 (de) 1988-11-10 1989-09-28 Verfahren zum Formen von Verbundstoff- Körpern mit Metallmatrix durch Dispersionsgiessen und Produkte daraus.
AT89630172T ATE109212T1 (de) 1988-11-10 1989-09-28 Verfahren zum formen von verbundstoff- körpern mit metallmatrix durch dispersionsgiessen und produkte daraus.
EP89630172A EP0368788B1 (en) 1988-11-10 1989-09-28 A method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby
KR1019890014117A KR0121456B1 (ko) 1988-11-10 1989-09-30 금속 기재 복합체를 제조하는 방법
IE318089A IE63876B1 (en) 1988-11-10 1989-10-04 A method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby
NO893987A NO177417C (no) 1988-11-10 1989-10-05 Framgangsmåte for framstilling av en metallmatrisekompositt
CA002000802A CA2000802C (en) 1988-11-10 1989-10-13 A method for forming metal matrix composite bodies with a dispersion casting technique and products produced thereby
FI894934A FI91492C (fi) 1988-11-10 1989-10-17 Menetelmä metallimatriisikomposiitin valmistamiseksi
NZ231074A NZ231074A (en) 1988-11-10 1989-10-19 Infusing filler with molten matrix metal and supplying additional matrix metal to infused filler
CN89108089A CN1065792C (zh) 1988-11-10 1989-10-21 用分散铸造技术制备金属基质复合体的方法
MX018188A MX172496B (es) 1988-11-10 1989-10-31 Metodo para fabricar un cuerpo compuesto de matriz de metal
BR898905612A BR8905612A (pt) 1988-11-10 1989-11-01 Um metodo para formacao de corpos compostos de matriz de metal com uma tecnica de fundicao por dispersao e produtos assim produzidos
PH39468A PH26121A (en) 1988-11-10 1989-11-07 Method forming metal matrix composition bodies with a dispersion casting technique and products produced thereby
DK559089A DK559089A (da) 1988-11-10 1989-11-09 Fremgangsmaade til fremstilling af metalmatrixkompositprodukter
PT92249A PT92249B (pt) 1988-11-10 1989-11-09 Processo para a modelacao de corpos compositos com matriz de metal com uma tecnica de moldacao por dispersao e produtos produzidos por esse processo
ZA898549A ZA898549B (en) 1988-11-10 1989-11-09 Forming metal matrix composite bodies with a dispersion casting technique
TR89/0759A TR25354A (tr) 1988-11-10 1989-11-09 DAGINIK DÖKüM TEKNIGIYLE METAL MATRIKS BILESIK CISIMLERININ KALIPLANDIRILMASI YÖNTEMI VE BU SURETLE ELDE EDILEN MAMULLER
RO142380A RO107122B1 (ro) 1988-11-10 1989-11-09 Procedeu de obtinere a corpurilor compozite, cu matrice metalica
JP1291368A JP2905520B2 (ja) 1988-11-10 1989-11-10 金属マトリックス複合体の形成方法
US07/672,064 US5222542A (en) 1988-11-10 1991-03-18 Method for forming metal matrix composite bodies with a dispersion casting technique

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US5172746A (en) * 1988-10-17 1992-12-22 Corwin John M Method of producing reinforced composite materials
US5193605A (en) * 1991-11-04 1993-03-16 The United States Of America As Represented By The Secretary Of The Navy Techniques for preparation of ingot metallurgical discontinuous composites
US5199481A (en) * 1988-10-17 1993-04-06 Chrysler Corp Method of producing reinforced composite materials
US5222542A (en) * 1988-11-10 1993-06-29 Lanxide Technology Company, Lp Method for forming metal matrix composite bodies with a dispersion casting technique
US5228494A (en) * 1992-05-01 1993-07-20 Rohatgi Pradeep K Synthesis of metal matrix composites containing flyash, graphite, glass, ceramics or other metals
US5240672A (en) * 1991-04-29 1993-08-31 Lanxide Technology Company, Lp Method for making graded composite bodies produced thereby
US5526914A (en) * 1994-04-12 1996-06-18 Lanxide Technology Company, Lp Brake rotors, clutch plates and like parts and methods for making the same
US5620791A (en) * 1992-04-03 1997-04-15 Lanxide Technology Company, Lp Brake rotors and methods for making the same
US5735332A (en) * 1992-09-17 1998-04-07 Coors Ceramics Company Method for making a ceramic metal composite
US6143421A (en) * 1992-09-17 2000-11-07 Coorstek, Inc. Electronic components incorporating ceramic-metal composites
US6270601B1 (en) 1998-11-02 2001-08-07 Coorstek, Inc. Method for producing filled vias in electronic components
US6338906B1 (en) 1992-09-17 2002-01-15 Coorstek, Inc. Metal-infiltrated ceramic seal
US6346317B1 (en) 1992-09-17 2002-02-12 Coorstek, Inc. Electronic components incorporating ceramic-metal composites
US20150232647A1 (en) * 2012-08-22 2015-08-20 Korea Institute Of Ceramic Engineering And Technology Carbon fiber composite coated with silicon carbide and production method for same
CN109848363A (zh) * 2019-01-14 2019-06-07 东莞理工学院 一种用于制备可溶性陶瓷模具的材料、可溶性陶瓷模具及其应用
CN115161509A (zh) * 2022-07-27 2022-10-11 哈尔滨工业大学 一种液相分散法制备纳米碳化硼增强铝基复合材料的方法

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GB9302921D0 (en) * 1993-02-13 1993-03-31 Atomic Energy Authority Uk Particulate metal matrix composites
JP4583334B2 (ja) * 2006-05-02 2010-11-17 啓治 山部 鋳造用の金属−セラミックス複合材料の製造法
JP5063176B2 (ja) * 2007-04-27 2012-10-31 日精樹脂工業株式会社 カーボンナノ複合金属材料の製造方法
CN109396422B (zh) * 2018-12-27 2019-09-27 吉林大学 一种小包内纳米颗粒预分散辅助熔体内均匀分散的方法

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Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5199481A (en) * 1988-10-17 1993-04-06 Chrysler Corp Method of producing reinforced composite materials
US5172746A (en) * 1988-10-17 1992-12-22 Corwin John M Method of producing reinforced composite materials
US5222542A (en) * 1988-11-10 1993-06-29 Lanxide Technology Company, Lp Method for forming metal matrix composite bodies with a dispersion casting technique
US5240672A (en) * 1991-04-29 1993-08-31 Lanxide Technology Company, Lp Method for making graded composite bodies produced thereby
US5372777A (en) * 1991-04-29 1994-12-13 Lanxide Technology Company, Lp Method for making graded composite bodies and bodies produced thereby
US5549151A (en) * 1991-04-29 1996-08-27 Lanxide Technology Company, Lp Method for making graded composite bodies and bodies produced thereby
US5193605A (en) * 1991-11-04 1993-03-16 The United States Of America As Represented By The Secretary Of The Navy Techniques for preparation of ingot metallurgical discontinuous composites
US5620791A (en) * 1992-04-03 1997-04-15 Lanxide Technology Company, Lp Brake rotors and methods for making the same
US5228494A (en) * 1992-05-01 1993-07-20 Rohatgi Pradeep K Synthesis of metal matrix composites containing flyash, graphite, glass, ceramics or other metals
US5735332A (en) * 1992-09-17 1998-04-07 Coors Ceramics Company Method for making a ceramic metal composite
US6143421A (en) * 1992-09-17 2000-11-07 Coorstek, Inc. Electronic components incorporating ceramic-metal composites
US6338906B1 (en) 1992-09-17 2002-01-15 Coorstek, Inc. Metal-infiltrated ceramic seal
US6346317B1 (en) 1992-09-17 2002-02-12 Coorstek, Inc. Electronic components incorporating ceramic-metal composites
US5526914A (en) * 1994-04-12 1996-06-18 Lanxide Technology Company, Lp Brake rotors, clutch plates and like parts and methods for making the same
US6270601B1 (en) 1998-11-02 2001-08-07 Coorstek, Inc. Method for producing filled vias in electronic components
US20150232647A1 (en) * 2012-08-22 2015-08-20 Korea Institute Of Ceramic Engineering And Technology Carbon fiber composite coated with silicon carbide and production method for same
US9631067B2 (en) * 2012-08-22 2017-04-25 Korea Institute Of Ceramic Engineering And Technology Carbon fiber composite coated with silicon carbide and production method for same
CN109848363A (zh) * 2019-01-14 2019-06-07 东莞理工学院 一种用于制备可溶性陶瓷模具的材料、可溶性陶瓷模具及其应用
CN115161509A (zh) * 2022-07-27 2022-10-11 哈尔滨工业大学 一种液相分散法制备纳米碳化硼增强铝基复合材料的方法
CN115161509B (zh) * 2022-07-27 2023-02-03 哈尔滨工业大学 一种液相分散法制备纳米碳化硼增强铝基复合材料的方法

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FI894934A0 (fi) 1989-10-17
ZA898549B (en) 1991-07-31
CN1065792C (zh) 2001-05-16
NO177417B (no) 1995-06-06
CA2000802A1 (en) 1990-05-10
IL91734A0 (en) 1990-06-10
FI91492C (fi) 1994-07-11
RO107122B1 (ro) 1993-09-30
EP0368788B1 (en) 1994-07-27
AU625093B2 (en) 1992-07-02
CA2000802C (en) 2001-05-15
NO893987L (no) 1990-05-11
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PT92249A (pt) 1990-05-31
DE68917087D1 (de) 1994-09-01
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PH26121A (en) 1992-02-24
PT92249B (pt) 1995-07-18
IL91734A (en) 1994-12-29
EP0368788A1 (en) 1990-05-16
TR25354A (tr) 1993-01-06
KR0121456B1 (ko) 1997-12-03
KR900007514A (ko) 1990-06-01
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MX172496B (es) 1993-12-17
BR8905612A (pt) 1990-06-05
JPH02247067A (ja) 1990-10-02
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IE893180L (en) 1990-05-10
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DE68917087T2 (de) 1994-11-10
ATE109212T1 (de) 1994-08-15

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